# US 2013/0280504 A1 · Laminated Articles Having Discontinuous Adhesive Regions

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- Number: US 2013/0280504 A1
- Document ID: US20130280504A1
- Status: Published application
- Kind: A1
- Application number: 13/851,761
- Filed: 2013-03-27
- Published: 2013-10-24
- Earliest claimed: 2012-03-28
- Assignees: W. L. Gore & Associates, Inc.
- Applicants: W. L. Gore & Associates, Inc.
- Inventors: William Kelsey
- Web page: https://patentgrep.com/patent/US20130280504A1

## CPC

- B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14)
- B32B 5/04: characterised by a layer being specifically extensible by reason of its structure or arrangement {, e.g. by reason of the chemical nature of the fibres or filaments}
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 38/0012: {Mechanical treatment, e.g. roughening, deforming, stretching}
- Y10T 428/24818: Knitted, with particular or differential bond sites or intersections
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Laminated articles that include a first textile and a functional film layer bonded together by an adhesive layer having a distinctive, discontinuous adhesive pattern is provided. The discontinuous adhesive pattern creates regions free or substantially free of adhesive that permits the laminate to preferentially bend in those regions. The adhesive regions, together with the non-adhesive regions, create a visible pattern on the surface of the laminate. A second textile may be bonded to the functional film layer opposing the first textile. The first textile or the film layer may be elastic, shrinkable, or expandable. In such embodiments, raised portions of the laminate corresponding to the non-adhesive regions and curled portions corresponding to the adhesive regions are visible. The laminated article is waterproof, liquid-proof, breathable, and aesthetically pleasing and demonstrates a reduction in stiffness, improved insulation properties, improved stretch properties and a reduction of noise associated with bending the article.

## Claims

### Claim 1

A laminated article comprising:
a functional film layer;
a first textile; and
a first adhesive layer bonding said functional film layer and said first textile, said first adhesive layer containing two or more adhesive regions separated by regions substantially free of adhesive, each said adhesive region containing a plurality of adhesive dots,
wherein a distance between adjacent adhesive dots within said adhesive regions is less than a distance between consecutive adhesive regions,
wherein said adhesive regions have at least one distinctive shape, and
wherein said laminate has a stretch force at 20% elongation of less than three times the stretch force of said first textile.

### Claim 2 (depends on 1)

The laminated article of claim 1, wherein said laminate has a stretch force at 20% elongation of less than two times the stretch force of said first textile.

### Claim 3 (depends on 1)

The laminated article of claim 1, wherein said laminate has a stretch force at 20% elongation of less than the stretch force of said first textile.

### Claim 4 (depends on 1)

The laminated article of claim 1, wherein said laminate has a stretch force at 20% elongation of less than 0.5 times the stretch force of said first textile.

### Claim 5 (depends on 1)

The laminated article of claim 1, wherein said laminate has a stretch force at 20% elongation of less than 0.33 times the stretch force of said first textile.

### Claim 6 (depends on 1)

The laminated article of claim 1, wherein said laminate has a stretch force at 20% elongation of less than 0.16 times the stretch force of said first textile.

### Claim 7 (depends on 1)

The laminated article of claim 1, wherein said plurality of adhesive dots are distributed non-uniformly within said adhesive regions.

### Claim 8 (depends on 1)

The laminated article of claim 1, wherein said functional film layer is a fluoropolymer.

### Claim 9 (depends on 1)

The laminated article of claim 1, wherein said functional film layer is selected from expanded polytetrafluoroethylene (ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 10 (depends on 1)

The laminated article of claim 1, wherein said functional film layer is waterproof and breathable.

### Claim 11 (depends on 1)

The laminated article of claim 1, wherein said plurality of adhesive dots each have substantially the same size.

### Claim 12 (depends on 1)

The laminated article of claim 1, wherein said adhesive dots differ in size within said adhesive regions.

### Claim 13 (depends on 1)

The laminated article of claim 1, wherein adhesive dots positioned on an outer portion of said adhesive regions have a diameter that is larger than adhesive dots positioned on an inner portion of said adhesive regions.

### Claim 14

A laminated article comprising:
a functional film layer;
a first textile; and
a first adhesive layer bonding said functional film layer and said first textile, said first adhesive layer containing adhesive regions and regions substantially free of adhesive, wherein said regions substantially free of adhesive are interspaced between said adhesive regions,
wherein said laminate has a stretch force at 20% elongation of less than three times the stretch force of said first textile.

### Claim 15 (depends on 14)

The laminated article of claim 14, wherein said laminate has a stretch force at 20% elongation of less than two times the stretch force of said first textile.

### Claim 16 (depends on 14)

The laminated article of claim 14, wherein said laminate has a stretch force at 20% elongation of less than the stretch force of said first textile.

### Claim 17 (depends on 14)

The laminated article of claim 14, wherein said laminate has a stretch force at 20% elongation of less than 0.5 times the stretch force of said first textile.

### Claim 18 (depends on 14)

The laminated article of claim 14, wherein said laminate has a stretch force at 20% elongation of less than 0.33 times the stretch force of said first textile.

### Claim 19 (depends on 14)

The laminated article of claim 14, wherein said laminate has a stretch force at 20% elongation of less than 0.16 times the stretch force of said first textile.

### Claim 20 (depends on 14)

The laminated article of claim 14, wherein said laminated article preferentially bends in said regions substantially free of adhesive.

### Claim 21 (depends on 14)

The laminated article of claim 14, wherein said regions substantially free of adhesive have a width greater than about 2 mm.

### Claim 22 (depends on 14)

The laminated article of claim 14, wherein said functional film layer is a fluoropolymer.

### Claim 23 (depends on 14)

The laminated article of claim 14, wherein said functional film layer is selected from expanded polytetrafluoroethylene (ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 24 (depends on 14)

The laminated article of claim 14, wherein at least one of said first adhesive regions comprise a substantially continuous band of adhesive surrounding a plurality of adhesive dots.

### Claim 25 (depends on 24)

The laminated article of claim 24, wherein said plurality of adhesive dots have substantially the same size.

### Claim 26 (depends on 24)

The laminated article of claim 24, wherein said plurality of adhesive dots differ in size.

### Claim 27 (depends on 14)

The laminated article of claim 14, wherein at least one of said first adhesive regions comprise strips of adhesive positioned within the adhesive region such that the strips of adhesive are substantially parallel to each other with said regions substantially free of adhesive interspacing said strips of adhesive.

### Claim 28 (depends on 14)

The laminated article of claim 14, wherein at least one of said first adhesive regions comprise centrally located regions that are free or substantially free of adhesive.

### Claim 29 (depends on 14)

The laminated article of claim 14, wherein said functional film layer is waterproof and breathable.

### Claim 30

A laminated article comprising:
a functional film layer;
a first textile; and
a first adhesive layer bonding said functional film layer and said first textile, said first adhesive layer containing first adhesive regions and second adhesive regions,
wherein said first adhesive regions contain an amount of adhesive that is greater than an amount of adhesive present in said second adhesive regions, and
wherein said laminate has a stretch force at 20% elongation of less than three times the stretch force of said first textile.

### Claim 31 (depends on 30)

The laminated article of claim 30, wherein said laminate has a stretch force at 20% elongation of less than two times the stretch force of said first textile.

### Claim 32 (depends on 30)

The laminated article of claim 30, wherein said laminate has a stretch force at 20% elongation of less than the stretch force of said first textile.

### Claim 33 (depends on 30)

The laminated article of claim 30, wherein said laminate has a stretch force at 20% elongation of less than 0.5 times the stretch force of said first textile.

### Claim 34 (depends on 30)

The laminated article of claim 30, wherein said laminate has a stretch force at 20% elongation of less than 0.33 times the stretch force of said first textile.

### Claim 35 (depends on 30)

The laminated article of claim 30, wherein said laminate has a stretch force at 20% elongation of less than 0.16 times the stretch force of said first textile.

### Claim 36 (depends on 30)

The laminated article of claim 30, wherein the distribution of adhesive within said first adhesive regions is non-uniform.

### Claim 37 (depends on 30)

The laminated article of claim 30, wherein said functional film layer is a fluoropolymer.

### Claim 38 (depends on 30)

The laminated article of claim 30, wherein said functional film layer is selected from expanded polytetrafluoroethylene (ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 39 (depends on 30)

The laminated article of claim 30, wherein said functional film layer is waterproof and breathable.

### Claim 40

A laminated article comprising:
a functional film layer;
a first textile bonded to said functional film layer by a first adhesive layer, said first adhesive layer containing at least one first region having a first percent area coverage of adhesive and at least one second region having a second percent area coverage of adhesive, said first percent area coverage of adhesive being greater than said second area coverage of adhesive,
wherein said first region forms at least one distinctive shape, said at least one shape being repeated two or more times and
wherein said laminate has a stretch force at 20% elongation of less than three times the stretch force of said first textile.

### Claim 41 (depends on 40)

The laminated article of claim 40, wherein said laminate has a stretch force at 20% elongation of less than two times the stretch force of said first textile.

### Claim 42 (depends on 40)

The laminated article of claim 40, wherein said laminate has a stretch force at 20% elongation of less than the stretch force of said first textile.

### Claim 43 (depends on 40)

The laminated article of claim 40, wherein said laminate has a stretch force at 20% elongation of less than 0.5 times the stretch force of said first textile.

### Claim 44 (depends on 40)

The laminated article of claim 40, wherein said laminate has a stretch force at 20% elongation of less than 0.33 times the stretch force of said first textile.

### Claim 45 (depends on 40)

The laminated article of claim 40, wherein said laminate has a stretch force at 20% elongation of less than 0.16 times the stretch force of said first textile.

### Claim 46 (depends on 40)

The laminated article of claim 40, wherein the distribution of adhesive within at least one of said first adhesive region and said second adhesive region is non-uniform.

### Claim 47 (depends on 40)

The laminated article of claim 40, wherein said functional film layer is a fluoropolymer.

### Claim 48 (depends on 40)

The laminated article of claim 40, wherein said functional film layer is selected from expanded polytetrafluoroethylene'(ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 49 (depends on 40)

The laminated article of claim 40, wherein said functional film layer is waterproof and breathable.

### Claim 50

A method of forming a laminated article comprising:
tensioning a first textile;
bonding a functional film layer and said first textile via a first adhesive layer, said first adhesive layer containing adhesive regions and regions substantially free of adhesive; and
allowing said first textile to relax resulting in curling of the laminated article in the areas corresponding to the adhesive regions,
wherein said regions substantially free of adhesive are interspaced between said adhesive regions and said adhesive regions have at least one distinctive shape,
wherein said laminated article preferentially bends in said regions substantially free of adhesive, and
wherein said laminate has a stretch force at 20% elongation of less than three times the stretch force of said first textile.

### Claim 51 (depends on 50)

The method of claim 50, wherein said laminate has a stretch force at 20% elongation of less than two times the stretch force of said first textile.

### Claim 52 (depends on 50)

The method of claim 50, wherein said laminate has a stretch force at 20% elongation of less than the stretch force of said first textile.

### Claim 53 (depends on 50)

The method of claim 50, wherein said laminate has a stretch force at 20% elongation of less than 0.5 times the stretch force of said first textile.

### Claim 54 (depends on 50)

The method of claim 50, wherein said laminate has a stretch force at 20% elongation of less than 0.33 times the stretch force of said first textile.

### Claim 55 (depends on 50)

The method of claim 50, wherein said laminate has a stretch force at 20% elongation of less than 0.16 times the stretch force of said first textile.

### Claim 56 (depends on 50)

The method of claim 50, wherein the distribution of adhesive within said first adhesive regions is non-uniform.

### Claim 57 (depends on 50)

The method of claim 50, wherein said functional film layer is a fluoropolymer.

### Claim 58 (depends on 50)

The method of claim 50, wherein a distance between consecutive said adhesive regions is greater than about 2 mm

### Claim 59 (depends on 50)

The method of claim 50, wherein said functional film layer is selected from expanded polytetrafluoroethylene (ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 60 (depends on 50)

The method of claim 50, wherein said functional film layer is waterproof and breathable.

### Claim 61

A method of forming a laminated article comprising:
tensioning a functional film layer;
bonding said tensioned functional film layer to a first textile via a first adhesive layer, said first adhesive layer containing adhesive regions and regions substantially free of adhesive to form a laminated article;
allowing said laminated article to relax resulting in curling of the laminated article in the areas corresponding to the adhesive regions,
wherein said regions substantially free of adhesive are interspaced between said adhesive regions and said adhesive regions have at least one distinctive shape, and
wherein said laminate has a stretch force at 20% elongation of less than three times the stretch force of said first textile.

### Claim 62 (depends on 61)

The method of claim 61, wherein said laminate has a stretch force at 20% elongation of less than two times the stretch force of said functional film layer.

### Claim 63 (depends on 61)

The method of claim 61, wherein said laminate has a stretch force at 20% elongation of less than the stretch force of said functional film layer.

### Claim 64 (depends on 61)

The method of claim 61, wherein said laminate has a stretch force at 20% elongation of less than 0.5 times the stretch force of said functional film layer.

### Claim 65 (depends on 61)

The method of claim 61, wherein said laminate has a stretch force at 20% elongation of less than 0.33 times the stretch force of said functional film layer.

### Claim 66 (depends on 61)

The method of claim 61, wherein said laminate has a stretch force at 20% elongation of less than 0.16 times the stretch force of said functional film layer.

### Claim 67 (depends on 61)

The method of claim 61, wherein a distance between consecutive said adhesive regions is greater than about 2 mm.

### Claim 68 (depends on 61)

The method of claim 61, wherein the distribution of adhesive within said first adhesive regions is non-uniform.

### Claim 69 (depends on 61)

The method of claim 61, wherein said functional film layer is a fluoropolymer.

### Claim 70 (depends on 61)

The method of claim 61, wherein said functional film layer is selected from expanded polytetrafluoroethylene (ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 71 (depends on 61)

The method of claim 61, wherein said functional film layer is waterproof and breathable.

### Claim 72 (depends on 61)

The method of claim 61, further comprising bonding an elastomeric film layer to said functional film layer prior to tensioning said functional film layer.

### Claim 73 (depends on 72)

The method of claim 72, wherein said functional film layer is selected from expanded polytetrafluoroethylene (ePTFE), expanded modified polytetrafluoroethylene, polytetrafluoroethylene (PTFE), ePTFE coated with a protective coating, PTFE coated with a protective coating, polyurethane and combinations thereof.

### Claim 74

A laminated article comprising:
a functional film layer;
a first textile; and
a first adhesive layer bonding said functional film layer and said first textile, said first adhesive layer containing adhesive regions and regions substantially free of adhesive, wherein said regions substantially free of adhesive are interspaced between said adhesive regions,
wherein the distribution of adhesive within said adhesive regions is non-uniform.

### Claim 75 (depends on 74)

The laminated article of claim 74, wherein said regions substantially free of adhesive have a width greater than about 2 mm.

### Claim 76

A method of forming a laminated article comprising:
bonding a shrinkable functional film layer to a first textile via a first adhesive layer to form a laminated article, said first adhesive layer containing adhesive regions and regions substantially free of adhesive;
shrinking said functional film, resulting in curling of the laminated article in the areas corresponding to the adhesive regions,
wherein said regions substantially free of adhesive are interspaced between said adhesive regions and said adhesive regions have at least one distinctive shape.

### Claim 77 (depends on 76)

The method of claim 76, wherein said laminated article curls towards the functional film layer.

### Claim 78 (depends on 76)

The method of claim 76, further comprising adhering a second textile to said shrunk functional film on a side of said shrunk functional film opposing said first textile.

### Claim 79

A method of forming a laminated article comprising:
bonding a functional film layer to a shrinkable textile via a first adhesive layer to form a laminated article, said first adhesive layer containing adhesive regions and regions substantially free of adhesive,
shrinking said textile, resulting in curling of the laminated article in the areas corresponding to the adhesive regions; and
wherein said regions substantially free of adhesive are interspaced between said adhesive regions and said adhesive regions have at least one distinctive shape.

### Claim 80 (depends on 79)

The method of claim 79, wherein said laminated article curls towards the shrunk textile.